Design And Analysis A New System For Duct Testing With The Smart Installation Method.

DESIGN AND ANALYSIS A NEW SYSTEM FOR DUCT TESTING WITH THE SMART INSTALLATION METHOD

SYUKUR BIN ABDUL KADIR

Thisreportpresentedin partial fulfillmentof therequirements for the graduation of Bachelor of Mechanical Engineering (Design &Innovation)

FakultiKejuruteraanMekanikal

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

i

“I declare that I had read this thesis and in our opinion this thesis is sufficient from the aspect of scope and quality for the purpose to be awarded Degree of Bachelor

Mechanical Engineering (Design and Innovation)”

Signature : ... Name of Coordinator I : MR. NAZRI HUZAIMI BIN ZAKARIA Date : ...

ii

“I hereby to declare that this project report entitle Development and Characterization of Design and Analysis a New System for Duct Testing with the Smart Installation Method

s written by me and is my own effort except the ideas and summaries which I have clarified their sources.”

Signature : ………

Author : SYUKUR BIN ABDUL KADIR Date : ………

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Special dedication to my family, supervisor, my friends and all that help me to finish my thesis.

iv

ACKNOWLEDGEMENT

Assalamualaikum w.t.h, and Salam Sejahtera. With the word Alhamdulillah and very gracefully thanks to ALLAH s.w.t, for give much blessing to me in equally well to complete this project. With His permission, I have success in facing the challenge any obstacle while in completing this project.

This appreciation is also given to my project supervisors Projek Sarjana Muda, Mr. Nazri Huzaimi bin Zakaria cause willing to take the idea of my project’s proposal to be one of the topic research in this Projek Sarjana Muda. And also thankful once again causes have much helping and guide me to complete the project.

I am also not forgetting the Quality Assurance Engineer En Hafidzul as much taught and provides a very meaningful experience in my industrial training. A very thankful to En Hafidzul cause allows me to take this project for my Projek Sarjana Muda.

Besides that, I would also thanks to my course mate especially Amiruddin bin Omar and Muhammad Ridhwan b. Mohd Talib cause much helping me handling the software. Finally, special conferment’s for my lovely families that have much support me from any since I’m starting my degree in UTeM.

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ABSTRACT

This research objective is to redesign an existing Duct Tester System with a smart installation that has been use in Quality Assurance at Salutary Avenue Company. To develop a new design from existing product need a process that relates to making a decision of deliberation in different of levels activity. The implementation from these process, it will create new design that can be more ergonomic with the worker that handling the system. This study was happened at the Industrial Training at Salutary Avenue Company. In three month period duration, the system is roughly understand the manually and the process details. From the acknowledgement and discussion with the supervisor, severalproblemsare identified from experience and complain from the customer. Therefore, from the problem taken, a solution of re-design the system which iswill be a body with smart installation. A smart installation here means the ability of the body part is more ergonomic while install the filter inside the body. Even the time taken to install the devices can be faster. At the end of this research, this design will be draw in details andwill beanalyze with computer software (FEA & CFD). These analysesmethod is used to measure and identified the strength and also the failure that may occur in the design detail drawing data. This process is important to make sure that the new design is safe to be use. Finally, the new concepts design is choose to be a best result following the methods that have been use in this project.

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ABSTRAK

Penyelidikan ini adalah salah satu usaha untuk mereka bentuk semula sistemujikaji lohong “Duct Testing” yangsediaadadengan konsep pemasanganpintaryangmana sistem inidigunapakaidi dalamBahagian Kualitidi syarikatSalutary Avenue. Kaedah-kaedah untuk membangunkanrekabentukbaruini adalahmeliputi proses-prosesyang berkaitan denganmembuatkeputusan melalui kaedah perbandingan yang berbezamengikut aktiviti setiapperingkat. Proses penambahbaikan ini akan akan mewujudkan reka bentuk baruyanglebihergonomikdenganpekerjayangakan mengendalikansistem tersebut. Kajian ini dilakukan berdasarkan permasalahan yang berlaku ketika tempoh 3 bulan Latihan Industri di syarikat ini. Semasa tempoh tersebut,segala pengetahuan mengenai sistem ini diperoleh dengan memahami manual dan butiran-butiran terperinci yang berkaitan. Setelah membuat beberapa perbincangan bersama Jurutera Kualiti merangkap penyelia, beberapamasalahdapat di kenalpasti daripada pengalamandanaduandaripada pelanggan. Olehitu, berdasarkanmasalahyang telah dikenalpasti, penjanaan semula reka bentuk sistem yang baru akan dilakukan dengan mengaplikasikan sistem pemasangan pintar. Pemasanganpintardisinibermaksud

mempunyai bahagian badanyang lebih ergonomikdimana

prosesmemasangpenapisdalam badan dapat dilakukan lebih cekap dan cepat. Oleh itu, masayang diambiluntuk memasangpenapis akanlebih cepat. Di akhir kajian ini, reka bentuk terperinci akandilukis dandianalisis denganperisian komputer(FEA & CFD) ANYSYS. Analisis ini adalahkaedahyangdigunakan untuk mengukurdanmengenal pastikekuatandanjugakegagalanyangmungkin berlakudalamrekabentuklukisan terperinci. Proses iniadalah pentinguntukmemastikanbahawarekabentukbaruadalahselamat untukdigunakan. Akhir sekali, reka bentuk sistem yang baru dipilih sebaagai hasil yang terbaik berdasarkan kaedah-kaedah yang digunapakai dalam projek ini.

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TABLE OF CONTENT

CHAPTER TITLE PAGE

CONFESSION i

DECLARATION ii

ACKNOWLEDGEMENT iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENT vii

LIST OF TABLE xii

LIST OF FIGURE xiii

LIST OF APPENDICES xvi

CHAPTER 1 INTRODUCTION 1

1.1 Background Company 1

1.2 Quality Management System 2

1.3 Duct Testing System 4

1.4Problem Statement 6

1.5 Objectives 7

viii

CHAPTER 2 LITERATURE REVIEW 8

2.1 Backgrounds 8

2.2 Wind Tunnel 9

2.3 Fluids Dynamics

102.3.1 Airflow in turbulent 10

2.3.2 Fluid Viscosity 11

2.3.3 Reynolds Number 11

2.3.4 Boundary Layers 13

2.4 Designs in Ducting

142.4.1 Open Circuit 142.4.2 Closed circuit 152.4.3 Fans

162.4.4 Settling Chamber 162.4.5 Honeycombs 16 2.4.6 Diffuser 17 2.4.7 Test Section 17

2.5 Testing Area with Application

182.5.1 Velocimeters/Observation Devices 18 2.5.2 Dust Feeder

192.5.3 Atomizer

Aerosol Generator 20

2.5.3.1 Principle

212.5.3.2 Technical Data

222.5.3.3 Other

Generators

(Series ATM) 22

2.5.4 Laser Aerosol Particle Counter 23

ix

CHAPTER 3 METHODOLOGY 27

3.1 Introduction 27

3.2 Flow Chart 28

3.3 Identifying the Tester andCustomer Need 29 3.3.1 Formulating a Design problem 30 3.4 Quality Function Deployment (QFD) 31

3.4.1 List of Need Statement 32

3.4.2 House of Quality

333.4.3 Summary 34

3.5 Product Design Specification 343.6 Morphological Chart 36

3.7 Design Tools 37

3.7.1 Rough 3D Drawing 37

3.8 CAE Analysis 38

3.8.1 Finite Element Analysis (FEA) 38 3.8.2 Computational Fluid Dynamics 39

3.8.3 Analyses Results 40

3.9 Conceptual Design 40

3.9.1 Concept 1 41

3.9.2 Concept 2 42

3.9.3 Concept 3 43

3.10 Weight decision Method

443.10.1 Summary in Selected Concept Design 46

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CHAPTER 4 DESIGN ANALYSIS AND RESULT 47

4.1 Introduction of Design Analysis 47 4.2 Target Outcome of Design Analysis 48

4.3 Overview of Detail Design 49

4.4 Finite Element Analysis (FEA)

Using ANSYS V12 54

4.4.1 Structure Analysis in

Existing Concepts (Acrylic 5mm) 56 4.4.2 Structure Analysis in Parameter 2

(Acrylic 8mm) 57

4.4.3 Structure Analysis inParameter 3

(Acrylic 10mm) 59

4.4.4 Calculation of Safety Factor 60

4.4.5 Analysis Summary 62

4.5 Computational Fluid Dynamic 63

4.5.1 Selection Concepts 64

4.5.2 Analysis Summary 65

4.6 Installation Method & Testing Procedure. 65 4.6.1 Installation (First Setup) 66

4.7 Maintenance 70

4.8 Cost Analysis 73

4.8.1 Material Used 73

4.8.2 Estimation Cost 75

xi

CHAPTER 5 DISCUSSION 78

5.1 Overview of Idea Improvement 78

5.2 Evaluating Results 81

5.2.1 Analysis Structure (Static & Flow) 81 5.2.2 Time and Man Power Reduction

in Process Installation 84

5.2.3 Cost Management 85

CHAPTER 6 CONCLUSION AND RECOMMENDATION 86

6.1 Conclusion 86

6.2 Recommendation 88

BIBLIOGRAPHY APPENDICES A Gantt chart B Details design

xii

LIST OF TABLE

NO TITLE PAGE

2.1 Technical Data of Aeorosol Generator 22

2.2 Summary of Application 24

3.1 House of Quality 33

3.2 Product Design Specification Characteristic 35

3.3 Morphological chart 36

3.3 Weight Decision Metric 45

4.1 Bill of Material (BOM) 52

4.2 Material Properties 55

4.3 Material Properties 55

4.4 Analysis Summary 62

4.5 Analysis Summary 65

4.6 Comparison Design in Maintenance 71

4.7 Estimation Cost by Each Component 75

xiii

LIST OF FIGURE

NO TITLE PAGE

1.1 Filter testing with existing Duct System 5

1.2 Testing area with equipment 5

2.1 Wind tunnel factory ventilation (right) 9

2.2 Experiment aircraft 9

2.3 Air flow pattern in ducting 12

2.4 Open circuit Ducting 14

2.5 Closed circuit Ducting 15

2.6 Testing Area Filter 17

2.7 Dust Feeder Application 19

2.8 Atomizer Aerosol Generator

202.9 Laser Aerosol Particle Counter 23

2.10 Arrangement of instruments Aerosol Generator ATM,

Dust Feeder 24

2.11 Airpak filter (Pre Filter) 26

2.12 XL FOLD Filter (fined filter) 26

xiv

3.1 Flow Chart 28

3.2 Information required for the production

of the product design specification (after Pugh, 1990) 34

3.3 Concept 1 41

3.4 Concept 2 42

3.5 Concept 3 43

3.6 Object Tree 44

4.1 Assembly Component 49

4.2 Exploded Components (inlet ducting) 50

4.3 Exploded Components (testing area) 50

4.4 Exploded Components (outlet ducting) 51

4.5 Inlet Ducting 53

4.6 Testing Area 53

4.7 Load Applied and Fixed support 54

4.8 Equivalent (Von-Mises) Stress after Analysis 56

4.9 Total Deformations after Analysis 56

4.10 Safety Factor of 5mm 57

4.11 Equivalent (Von-Mises) Stress after Analysis 57

4.12 Total Deformations after Analysis 58

4.13 Safety Factor of 8mm 58

4.14 Equivalent (Von-Mises) Stress after Analysis 59

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4.16 Safety Factor of 10mm 60

4.17 Comparison Design in Sketching 63

4.18 Velocity Streamlines Concepts 1 64

4.19 Velocity Streamlines Concepts 2 64

4.20 Process 1 66

4.21 Process 2 67

4.23 Process 3 68

4.24 Worker Crawl inside Ducting to Clean Up Mud 70

4.25 Inlet Area 71

4.26 Testing Area 72

4.27 Outlet Area 72

4.28 Standard Part 74

5.1 Flow Generation Idea

795.2 Flow Selected Concepts to Details Design 80

5.3 Graph Von Mises vs. Parameter 82

5.4 Graph Deformation vs. Parameter 82

xvi

LIST OF APPENDICES

NO. TITLE

A Gantt chart PSM I and II

B Details Design

CHAPTER 1

INTRODUCTION

1.1 BACKGROUND COMPANY

Salutary Avenue Manufacturing Services SdnBhd (SAM) is established in the early 90s with networks throughout the region and having its headquarters in Malaysia. The Company specializes in designing, manufacturing, installing and monitoring of filters for the application in the power and oil and gas industries.

The companies were awarded the prestigious ISO 9001:2000 in August 2003 by Lloyd's Register Quality Assurance and the scope of Quality Management System is applicable to design, development and manufacture of intake air filter and liquid filter.SAM possesses the technical know-how and manufacturing capabilities to produce top quality filters to cater for customers' requirements. The R&D teams are categorized into three divisions namely:-

i. Product Improvement Team looks into the ongoing improvements of existing products

ii. New Product Development Team develops new filter ranges which are widely used by our customers or required by them in order to solve existing problems

iii. Product Marketing and Promotion Team is responsible to create awareness to customers on the new developments in the R&D by conducting presentations, road shows and site visits

2

This company has close collaborations with local institutions for updating and developing latest technologies and utilizing their facilities. The company also have own in-house testing facilities which conform to international standard. Several plants with an overall land area of 60,000 sq. feet, equipped with machinery, fittings and related facilities. The existing production capacity today is 800,000 units yearly and able to facilitate further for twice the existing capacity and also provide technical and consultation services as follows:-

i. Technical presentation on filter fundamentals, awareness and knowledge to educate engineers andend-users

ii. Perform data analysis on filter efficiency and savings on cost of energy iii. Continuous technical support and professional advice on filter

The company also offers packaged services such as monitoring and inspection of the filters so as to ensure their consistent maximum performance. Monitoring is crucial

i. To eliminate any unnecessary maintenance to gas turbine and turbo compressors

ii. To ensure low power consumption cost by reducing maintenance cost resulting from premature shut down of gas turbine

1.2 QUALITY MANAGEMENT SYSTEM

The aims of the Quality Department are to get things right the first time every time and to provide a platform on which consistent improvement can be developed. These include the establishment of a good quality management system and the assessment of its adequacy, the auditing of the operation of the system, and the review of the system itself. The application of a quality management system is seen to be a useful framework, which can provide better control and significant improvements of all activities.

3

The management of Salutary Avenue is committed to the design and production of filter that is fit for its purpose, highest quality consistent with its performance and offers safety and reliability at the optimum price and product availability. This is achieved by operating and maintaining a comprehensive quality control system based on ISO 9001:2000. The system is fully documented and has taken place in three stages as categorized below:-

 Quality Inspection

 A group of inspectors and checkers is available to perform tests and comparison of the product with the standard. This was applied at all stages covering the raw material received, production process and delivery. The purposes of the inspection is to identify defects found during inspection and segregates them for scrapped, reworks or degrade to second products.

 Quality Assurance

 Quality Assurance contains all the previous stages in order to provide sufficient confidence that our product or service satisfy customer’s needs. Other activities such as comprehensive quality manuals, analysis of data, development of process controls and auditing of quality systems is also developed. At this stage there was also an emphasis of chance from detection activities towards prevention of bad quality products.

4

1.3 DUCT TESTING SYSTEM

Air filter test rig dust feeder fitted with vibrating tray to add measured quantity of the dust. 200mm dia. Ducting will be used in test equipment. Duct fitted with piezometer ring on the upstream and downstream for measurement of pressure drop across the test filter. Provision is for the mounting of test filter. Test filter housing suitable to mount filter of 980mmheight. Ducting mounted on trolley for easy mounting of test filter and loading and unloading of HEPA filter. Provision is for the mounting of HEPA filter with conical duct at both ends. Airflow measuring unit is apply with orifice plate and pressure tapping across it. And the Butterfly valve is to adjust different flow rate. Blower impeller directly mounted on the shaft of the motor. Tapping for particle counter fitted with solenoid valve for taking upstream and downstream count. Control panel for the above. Air filter test rig. The performance air filter test rig that is designed to serve various industrial applications. Outfitted with various attributes, this fuel filter testing rig is manufactured from high quality material.

During the test, the particle size efficiency isdetermined on the flat sheet filter medium usingthe particle counting method.Specimens of the sheet filter medium are fixedin a test filter assembly and subject to the testair flow corresponding to the prescribed filtermedium velocity. The test aerosol from theaerosol generator is conditioned then neutralized,mixed homogeneously with filtered test air andled to the test filter assembly.In order to determine the efficiency, partial flowsof the test aerosol are sampled upstream anddownstream of the filter medium.Using a particle counting instrument, thenumber concentration of the particles containedis determined for the various particle sizes.The results of these measurements are used todraw a graph of penetration against particle sizefor which the penetration is a maximum.

5

Figures 1.1: Filter testing with existing Duct System

Figures 1.2: Testing area with equipment

6

The data problem statements are getting from the customer complaint with Salutary Avenue Companyand from the experience while handling the system in my Industrial Training. For the complaint document is not provide in this report because it be the confidential.

The major problem is the time taken while handling the system which in term of installing the filter, running the test and collecting data. The time process are not ergonomics that means the scientific discipline concerned with the understanding of interactions among humans and other elements of a system, and the profession that applies theory, principles, data and methods to design in order to optimize human well-being and overall system performance.

Tocomplete the testing procedure or step, it must need at least three people to in charge the process. The new target for the new ducting system will capable running only uses 2 or 1 person. By reducing man power it also affected the cost in implementation the quality testing.

Another problem that occurs in the duct testing system is the design problem. The old design have difficult problem in maintenance. For the maintenance, after completing the dust and water testing the problems happen in cleaning up the body. And the leaking problem in piping also occurs after the test.

The body is capable to test only 2 stage filter, meanwhile the customer request the process are in 3 stage in one time process which is include pre, fined and HEPA filters.

Due to the problem, a study and analysis for the existing product must be done to make the improvement of duct testing design with smart installation. A new design is expected to solve the problems that happen earlier.

7

The objectives of this study are to design and analysis a new duct system testing with a new concept of duct system by focusing on smart installation method.

1.6 SCOPE OF PROJECT

The scopes for this project are:

i. Study and analyze the existing design of ducting system.

ii. Design a new concept of duct testing system with smart installation method.

This company has close collaborations with local institutions for updating and developing latest technologies and utilizing their facilities. The company also have own in-house testing facilities which conform to international standard. Several plants with an overall land area of 60,000 sq. feet, equipped with machinery, fittings and related facilities. The existing production capacity today is 800,000 units yearly and able to facilitate further for twice the existing capacity and also provide technical and consultation services as follows:-

i. Technical presentation on filter fundamentals, awareness and knowledge to educate engineers andend-users

ii. Perform data analysis on filter efficiency and savings on cost of energy iii. Continuous technical support and professional advice on filter

The company also offers packaged services such as monitoring and inspection of the filters so as to ensure their consistent maximum performance. Monitoring is crucial

i. To eliminate any unnecessary maintenance to gas turbine and turbo compressors

ii. To ensure low power consumption cost by reducing maintenance cost resulting from premature shut down of gas turbine

1.2 QUALITY MANAGEMENT SYSTEM

The aims of the Quality Department are to get things right the first time every time and to provide a platform on which consistent improvement can be developed. These include the establishment of a good quality management system and the assessment of its adequacy, the auditing of the operation of the system, and the review of the system itself. The application of a quality management system is seen to be a useful framework, which can provide better control and significant improvements of all activities.

The management of Salutary Avenue is committed to the design and production of filter that is fit for its purpose, highest quality consistent with its performance and offers safety and reliability at the optimum price and product availability. This is achieved by operating and maintaining a comprehensive quality control system based on ISO 9001:2000. The system is fully documented and has taken place in three stages as categorized below:-

 Quality Inspection

 A group of inspectors and checkers is available to perform tests and comparison of the product with the standard. This was applied at all stages covering the raw material received, production process and delivery. The purposes of the inspection is to identify defects found during inspection and segregates them for scrapped, reworks or degrade to second products.

 Quality Assurance

 Quality Assurance contains all the previous stages in order to provide sufficient confidence that our product or service satisfy customer’s needs. Other activities such as comprehensive quality manuals, analysis of data, development of process controls and auditing of quality systems is also developed. At this stage there was also an emphasis of chance from detection activities towards prevention of bad quality products.

1.3 DUCT TESTING SYSTEM

Air filter test rig dust feeder fitted with vibrating tray to add measured quantity of the dust. 200mm dia. Ducting will be used in test equipment. Duct fitted with piezometer ring on the upstream and downstream for measurement of pressure drop across the test filter. Provision is for the mounting of test filter. Test filter housing suitable to mount filter of 980mmheight. Ducting mounted on trolley for easy mounting of test filter and loading and unloading of HEPA filter. Provision is for the mounting of HEPA filter with conical duct at both ends. Airflow measuring unit is apply with orifice plate and pressure tapping across it. And the Butterfly valve is to adjust different flow rate. Blower impeller directly mounted on the shaft of the motor. Tapping for particle counter fitted with solenoid valve for taking upstream and downstream count. Control panel for the above. Air filter test rig. The performance air filter test rig that is designed to serve various industrial applications. Outfitted with various attributes, this fuel filter testing rig is manufactured from high quality material.

During the test, the particle size efficiency isdetermined on the flat sheet filter medium usingthe particle counting method.Specimens of the sheet filter medium are fixedin a test filter assembly and subject to the testair flow corresponding to the prescribed filtermedium velocity. The test aerosol from theaerosol generator is conditioned then neutralized,mixed homogeneously with filtered test air andled to the test filter assembly.In order to determine the efficiency, partial flowsof the test aerosol are sampled upstream anddownstream of the filter medium.Using a particle counting instrument, thenumber concentration of the particles containedis determined for the various particle sizes.The results of these measurements are used todraw a graph of penetration against particle sizefor which the penetration is a maximum.

Figures 1.1: Filter testing with existing Duct System

Figures 1.2: Testing area with equipment

The data problem statements are getting from the customer complaint with Salutary Avenue Companyand from the experience while handling the system in my Industrial Training. For the complaint document is not provide in this report because it be the confidential.

The major problem is the time taken while handling the system which in term of installing the filter, running the test and collecting data. The time process are not ergonomics that means the scientific discipline concerned with the understanding of interactions among humans and other elements of a system, and the profession that applies theory, principles, data and methods to design in order to optimize human well-being and overall system performance.

Tocomplete the testing procedure or step, it must need at least three people to in charge the process. The new target for the new ducting system will capable running only uses 2 or 1 person. By reducing man power it also affected the cost in implementation the quality testing.

Another problem that occurs in the duct testing system is the design problem. The old design have difficult problem in maintenance. For the maintenance, after completing the dust and water testing the problems happen in cleaning up the body. And the leaking problem in piping also occurs after the test.

The body is capable to test only 2 stage filter, meanwhile the customer request the process are in 3 stage in one time process which is include pre, fined and HEPA filters.

Due to the problem, a study and analysis for the existing product must be done to make the improvement of duct testing design with smart installation. A new design is expected to solve the problems that happen earlier.

The objectives of this study are to design and analysis a new duct system testing with a new concept of duct system by focusing on smart installation method.

1.6 SCOPE OF PROJECT

The scopes for this project are:

i. Study and analyze the existing design of ducting system.

ii. Design a new concept of duct testing system with smart installation method.